REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a Continuation-In-Part of a Russian Federation Patent Application No. 93053302 which was filed in the Patent Office of the Russian Feder¬ ation on November 26, 1993, for inventor Sergey Buligenovich Akpanbetov, for which priority is claimed under 35 USC 119.

BACKGROUND OF THE INVENTION

This invention comprises both method and apparatus for the manufacture of ozone from a gas that contains oxygen therein, such as, for example, atmospheric air, rela¬ tively pure oxygen, and other oxygen containing gases. The process is carried out by flowing the oxygen containing gas along a passageway within which lattice members having electrically energized electrodes, made in accordance with this invention, are arranged therein to contact the flowing gas and to excite the oxygen molecules thereof in such a man¬ ner that the energy imparted into the diatomic oxygen, hereinafter called oxygen, results in the formation of triatomic oxygen, hereinafter referred to as ozone.

The apparatus of this invention is made by surrounding an electrical conduc¬ tor, such as metallic rod, with a dielectric material, such as a ceramic that has little or no piezoelectric properties, or a crystalline material that does have piezoelectric properties.

The piezoelectric electric effect appears to be treated as a problem when it is encountered in some prior art ozone generators. The prior art recognizes and attempts to minimize the effects induced by the piezoelectric properties in ozone generators due to harmonic motion of the apparatus causing cracking, fracturing, and breaking of the dielectric material that surrounds the electrodes. The patents to Masuda et al, US No. 4,672,503 and to Conrad, US No. 5,130,003, are examples of this problem, to which refer¬ ence is made for further background of this invention.

One embodiment of this invention proceeds opposite to the prior art by enhancing these piezoelectric properties, and thereby bringing about unforeseen results

leading to unexpected advantages in an ozone generator that manufactures ozone from an oxygen containing gas by the employment of resonate frequencies that are induced by the selected combination of a power supply, the size and composition of the electrode dielectric, and the arrangement of the electrical conductors thereof, along with other variables related to the design and fabrication of an ozone generator

This desirable phenomena may be the result of resonate frequencies induced by the inductance or magnetic field that surrounds each of the electrodes of the ozone generator causing the adjacent electrodes to alternately attract and repel one another On the other hand it may be a combination of the resonance frequencies together with the piezoelectric properties of the dielectric material of the electrodes Further, the geometrical configuration of the lattice members of the ozone generator, and the arrangement of the electrodes thereof, combine with these other considerations to jointly contribute to the success of the present apparatus and process

In any event, the electrodes, regardless of the nature of the dielectric, stabilizes the electrical discharge, which is in the form of a corona, and thereby increases the conversion of oxygen into ozone, reduces the power requirements, as well as providing a structure which can be manufactured inexpensively

Throughout this disclosure the term "feed gas", or the equivalent thereof, refers to a gaseous mixture having oxygen therein The feed gas will sometime include a trace of ozone therein because ambient air, which often will be the feed gas, usually has at least a trace of ozone therein

SUMMARY OF THE INVENTION

This specification sets forth the precise invention for which a patent is solicited, in such manner as to distinguish it from other inventions and from what is old This invention comprehends both method and apparatus for manufacturing ozone from atmospheric air, or from an oxygen enriched fluid, using electrical energy for changing the 0 ₂ , or ordinary air, into O ₃ , or ozone

Broadly, this invention increases the reliability and decreases the cost of ozone generating processes by decreasing the relative size of the ozone generator apparatus, and at the same time increases the efficiency of conversion while simplifying the construction of the generator device This is achieved by the present method of ozone

that is carried out by the provision of an apparatus having spaced electrodes that form mutu¬ ally coroning barrier surface discharges therebetween that occurs as a result of applying high frequency voltage pulses thereto, whereby the flow of the oxygen feed gas between the spaced apart electrodes intimately subjects the oxygen molecules to the surface corona dis- 5 charges and converts the oxygen into ozone.

Applicant has discovered that an unusually effective flat corona discharge is uniformly generated when more than three co-planar electrodes are placed in the same plane and the distance between these spaced apart electrodes is judiciously selected for optimum results. if' In one embodiment of this invention, the distance between these spaced apart electrodes is not less than five times the width of the electrical conductor that forms the electrode, and not more than ten times the width of the electrode; and, the feed gas flows athwart the discharge plane of the electrodes in a manner to subject the oxygen molecules to the energy dissipated by the corona discharge.

15 Further, additional corona discharge is generated by the addition of other co- planar electrodes that are placed in the same plane and at a distance from the first recited co-planar electrodes. This allows the application of a greater voltage between the main and the additional electrodes rather than between any pair of adjacent electrodes for the generat¬ ing of a higher energy discharge.

2d Another important feature of this invention is the construction of an ozone generator having an enclosed stack of alternating electrodes, with the electrodes having mutually opposite electric potential which are rotated one from another in 180 degrees and covered by a dielectric separator. This configuration differs from existing prior art appara¬ tus in that the electrodes are longitudinally disposed members, such as round rods, for ex-

2 ^' , ample, and the dielectric separator has the form of a flat lattice or grid member for holding the electrodes anchored within its own dielectric material.

The above mentioned goal is also achieved by the selection of a thermo-con- ductive dielectric separator made of ceramic material. In one embodiment of the invention the selected dielectric is made of alumina ceramic material. In another embodiment of the j-- invention the selected dielectric is a piezoelectric material.

The above mentioned goal is achieved also with the placement of another one or more additional dielectric lattice members containing the same set of alternating

electrodes in parallel to the preceding one, and being displaced horizontally by half the dis¬ tance measured between the electrodes embedded within the dielectric of each lattice. The distance between the main and the additional dielectric separator is equal to the distance between the rods in any lattice. In this instance the nearest three adjacent electrodes selected from two adjacent lattice form an equilateral triangle.

A primary object of the present invention is the provision of method and apparatus for the formation of ozone from atmospheric air, or oxygen enriched fluid, using electrical energy for changing 02, including the oxygen in ordinary air, into 03, or ozone. Another object of this invention is to increase the reliability and to decrease the cost of ozone generating processes by decreasing the relative size of the generator, and at the same time increasing the efficiency and the simplification of the construction of the ozone generator device.

A further object of this invention is to disclose and provide mutually coron¬ ing barrier surface discharges between the dielectric of a plurality of spaced apart electrodes made in accordance with this invention, wherein high frequency voltage pulses are applied to the electrodes, while the flow of an oxygen containing fluid, such as air, occurs between the spaced plurality of ceramic encased electrodes, such that a flat corona discharge is gen¬ erated when more than three co-planar ceramic covered electrodes are placed in the same plane. An additional object of the present invention is the provision of a dielectric framework that supports electrodes therein, the distance between the electrodes being not less than five times the width of the electrode and not more than ten times the width of the electrode, and the air flows athwart the discharge plane of the electrode.

A further object of this invention is to arrange a plurality of lattice members having spaced apart parallel electrodes, made in accordance with this invention, such that a flat corona discharge is generated when more than three co-planar electrodes are placed in the same plane, and the distance between the electrodes is selected to enable additional corona discharges to be generated to provide the mutual coroning of the main and the addi¬ tional discharges, and with applying of a greater voltage between the main and the addi- tional electrodes than between any pair of adjacent electrodes for the generating of an addi¬ tional discharge; and, wherein high frequency voltage pulses are applied to the electrodes,

while the flow of an oxygen containing fluid, such as air, occurs between the spaced plurality of electrodes and is converted into ozone with good yields.

Another and still further object of this invention is the provision of an ozone generator comprising an enclosed stack of alternating electrodes having mutually opposite electric potential which are rotated one from another in 180 degrees and covered by a dielectric separator. The conductors of the electrodes are longitudinally extending rods, and the dielectric separator has the form of a flat lattice that holds the electrodes inside its own rods. The material of dielectric separator is a thermo-conductive ceramic

A still further object of this invention is to arrange the placement of another one or more additional dielectric separators containing the same sets of alternating electrodes in parallel to the preceding one and being displaced horizontally by the distance of a half the distance between the rods in each lattice. The distance between the main and the additional dielectric separators being equal to the distance between the rods in any lattice. These and various other objects and advantages of the invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings The above objects are attained in accordance with the present invention by the provision of method which is practiced by using apparatus fabricated in a manner substantially as described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a longitudinal cross-sectional representation of the preferred form of apparatus made in accordance with this invention;

Figure 2 is part diagrammatical, part schematical, part cross-sectional, top plan view of another apparatus similar to Figure 1; Figure 3 is a part cross sectional representation taken along line 3-3 of

Figure 1;

Figure 4 is a part cross-sectional side view of Figure 2;

Figure 5 is a part cross-sectional representation of a part of the apparatus disclosed in Figure 6; Figure 6 is a longitudinal, part cross-sectional view of a second embodiment of the invention, with some parts being removed therefrom, and some of the remaining parts

being shown in cross-section;

Figure 7 is an enlarged cross-sectional view of part of the apparatus of Figure 6;

Figure 8 is a further enlarged cross-sectional view of part of Figure 7; Figure 9 is a part diagrammatical, part schematical representation of the power characteristics of parts of this invention; and,

Figure 10 is a longitudinal part cross-sectional view of a second embodiment of the invention, with some parts being removed therefrom, and some of the remaining parts being shown in cross-section.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The attached drawing illustrates schematically, and as several examples, the preferred embodiments of the method and apparatus for manufacturing ozone according to this invention. This invention provides an improved apparatus for carrying out a method for the generation of ozone. The apparatus includes at least one lattice member having a monolithic body of a configuration to support a plurality of parallel electrodes therein. The apparatus is made of a dielectric material within which a plurality of electrodes are encased, with there being passageways between the electrodes through which gas can flow. Referring to the drawings, and in particular Figure 1 , together with Figures

2-4, there is a main housing 1 that forms an enclosure or case within which there is received a lattice member 2 made of dielectric material, such as a thermal conductive ceramic, as for example, alumina of the following composition: 94% A1 ₂ 0 ₃ , 0.02% Na ₂ 0, 5% Si0 ₂ , 0.03% MgO, and 0.05% other material. The lattice member 2, has a plurality of spaced parallel co-extending electrodes as seen at 3 and 4. The individual electrodes 3 and 4 are in the form of the illustrated electrical conductors and are spaced apart from one another and encased within thermal conductive ceramic material 5. Between adjacent electrodes are the illustrated fluid passageways P. Adjacent electrodes 3 and 4 of the lattice member 2 are of opposite polarity, as will be more fully discussed later on.

As best seen in Figure 4, there are a plurality of lattice members 2 and 6 stacked together in sandwiched relationship, with the adjacent electrodes 3, 4 and 8, 9 of

each lattice member 2 and 6 being spaced equidistant from one another It can also be seen in Figure 4 that any three adjacent electrodes of any two adjacent lattice members can likewise be spaced equidistant from one another and thereby form an equilateral triangle therebetween This arrangement forms a tortious flow path between the plurality of electrodes of the plurality of lattice members, and further arranges all of the electrodes of all of the lattice members for optimum discharge

In Figure 4, the dielectric insulator 7 that encases the electrodes 8 of the lattice members 2 and 6 may be flat, oblate, a polygon, or round as shown The adjacent electrodes 8 and 9 of the lattice members 2 and 6 are spaced distance LI apart, wherein LI is more that five times the electrode width and less than ten times the electrode width Note in Figure 3 that L is the distance between adjacent electrodes 3 and 4 of the lattice member 2, for example, and that the electrodes are connected to the power supply (see Figure 1 ) to provide alternate adjacent electrodes with an electrical potential of opposite polarity (see Figure 7) The conductors that form electrodes 8 and 9 are connected across the output of the power supply, with the conductor 9 being grounded The power supply 10 preferably has output characteristics shown in Figure 9, wherein current flows only a portion of the interval of each cycle

The second embodiment 1 10 of the invention, as illustrated in Figure 5, is in the form of a lattice member 12 of integral construction that provides a monolithic structure

The lattice member 12 is of a flat rectangular configuration having an outer rectangular marginal edge portion 14 that forms an enlarged boundary or frame for supporting the electrodes 30, 34 therefrom The electrodes extend parallel to one another and between the top 16 and bottom 18 The electrodes have opposed ends that terminate in the opposed sides 20, 22 that also form part of the enlarged boundary or frame

Ports or voids 24 are formed on either side of each of the bodies 26 for fluid flow therethrough The ports or voids 24 extend between the opposed sides 20, 22 Hence, there is an electrode receiving body 26 formed between each of the ports 24 and attached to the opposed sides 20, 22 of the frame Electrical conductors 28 and 32, respectively, connect alternate ones of the imbedded electrodes 30 and 34, respectively, to the power supply 10 Accordingly, this arrangement results in any pair of adjacent electrodes of the same lattice member always

being of opposite potential respective to each other.

Figure 6 illustrates a plurality of lattice members arranged in sandwiched relationship respective to one another. The enlarged peripheral edge 16, 18, 20, 22 of lat¬ tice member 12 forms intermediate chambers 36 and 38 between adjacent lattice members 12 to facilitate intimate contact of the oxygen as it flows across each of the ceramic encased electrodes. Longitudinal passageways 40 extend through the center of each of the ceramic electrode holders 26 for receiving an electrode 30 or 34 therein, with the free end of the electrodes each terminating short of the conductor bus 28 or 32 of opposite potential, as the case may be. It would be preferred to encase the electrode within the dielectric material during the baking of the ceramic material, rather than subsequently inserting the electrodes 30, 34 into the holes 40, as discussed.

The opposed faces 42 and 44 of the dielectric material of each electrode 26 has a baked coating of ceramic material applied thereto that results in a smooth enamel-like surface extending from one to the other opposed marginal edges 20, 22 of the lattice mem¬ ber. The other two opposed faces, 46 and 48, of the dielectric material that encases the electrodes 26 are not coated, and form the surfaces that defines the air passageways through the lattice members.

Enclosure 50 of Figure 6 forms a suitable housing within which a module made up of a plurality of monolithic lattice members 12 of the embodiment 1 10 is received. Feed gas inlet 52 is connected to inlet chamber 54 which in turn is arranged to direct the flow the oxygen containing feed gas into the spaces 24 of the first lattice member 12. As the feed gas continues through the spaces 24 between adjacent electrodes, some of the oxy¬ gen is converted into ozone which exits the module together with the remaining products of the unconverted gas and enters the exhaust chamber 56. The processed gas is free to be dis¬ charged at 58 and collected as ozone enriched fluid.

In Figure 7 numeral 60 indicates the flow path of the of the feed gas as it flows athwart, or more or less perpendicular respective to the electrodes of the lattice mem¬ bers 12. Figure 9 indicates one possible configuration of the wave form of the power supply 10 (Figures 1 and 5) that has worked satisfactory with a module made up of lattice members arranged in the manner of Figure 6. The individual lattice members are of rectan-

gular configuration and have an overall dimension of 6.5 cm X 15 cm, and are 0.5 cm thick at the border, with there being 26 electrodes, having conductor holes about 0.10 cm in diameter and the windows between conductors are about 5.3 cm long and 0.2 cm wide. The ceramic covered electrode is 0.3 cm thick which places the electrodes on 0.5 cm cen- ters. The effective length of the electrode is equal to the length of the window. It is noted in Figure 9 that the current flow occurs for approximately 10% of the half cycle duration.

This invention preferably is carried out by assembling a plurality of the ele¬ ments arranged in sandwiched relationship respective to one another, and in the manner of Figure 6, to provide a module that is placed within an enclosure 50 that facilitates the pas- sage of feed gas containing oxygen therethrough

The combination of this invention provides a stable electrical discharge which consequently provides a constant ozone concentration flowing therefrom. The edge effects at the ends of the lattice members that heretofore cause the creation of conductive bridges from the existing dust, and which heretofore add a leakage of the electrical potential weak- ening the discharge power is overcome by this invention so that the integrity of the ozone concentration is not violated. The plates are assembled in a stack, and while the separate distances may not always be the exact parallelity of the electrodes desired, the affects of the homogeneity of the ozone concentration is unexpectedly improved.